Die for molding insulating materials



July l5, 1930. T. A. BOTH DIE FOR MOLDING INSULATING MATERIALS -Fiied Nov. 4. 192e 3 Sheets-Sheet 1 July 15, 1930.

T. A. BOTH DIE FOR MOLDING INSULATING MATERIALS Filed Nov. 4. 1926 3 Sheets-Sheet 2 July v15, 1930. T. A. BOTH DIE FOR MOLDNG INSULATING MATRIALS Filed Nov. 4. 1926 3 Sheets-Sheet 3 Erg, ,74.

atbouwgs PatentedrJuly 15, 1930 ToNJns A. BCTII, or sTRATFoRD, CONNECTICUT, Assi'cfNoie To Tiin/ NTOFHCE ELECTRIC MANUFACTURING COMPANY', kon BRIDGEPCRT,CONNECTICUT, 'A Conro- RATICN CONNECTICUT Din IoRlIvIoLnING iNsULATING MATERIALS Application filed `November rlhis invention relates to a die for molding insulating material, and more specifically to a die for molding cover plates for the gang installation of electrical devices, suchas, for

example, a Vplurality of switches mounted in a single outlet box, and has for its principal object to provide a die which may be adjusted so thatthe same` die may be used to mo'ld j diii'erentsized plates, that is, plates for; use with different numbers of electrical devices, and it is, therefore, not necessary-to form a plurality of dies to `mold different sizes or lengths of plates as al1 the plates may beV made in the same die.

IVith the foregoing and other'v objects in view, I have devised a construction, the preferred form of which is illustrated in the accompanying drawings, forming a part of this specification. In these drawings,

Fig. l is atop plan view of the die coni-v lete. p Fig. 2 is alongitudina'l section thereof substantially onlineQ--Q of Fig. 1.

Fig. 3 is a transverse section substantially on line 3-3 of Fig. l.A I v Fig. 4: is a longitudinal section of thelower portion of the die at one end thereof, and the upper portion of the die in elevation. Fig. 5 is a view similar to Fig. 4, but showing some of the die sections removed and the end filler piece in position. Y

Fig. 6 is atop plan view of` one of the die sections as used for a two gang section of the plate. V1

Fig. 7 is an end view thereof. .e

Fig. 8 is atop plan view of the die section for a single gang and used at the end of the plate.` U

Fig. 9 is a side elevation thereof.

Fig. 10 is an end view thereof.

Fig. 11 is atop plan view of the filler piece for use in forming the end of the plate when a plate smaller than the capacity of the die is made.` Y

Fig. l2 is a transverse section thereof substantially on line 12``12 of Fig. 1 1.

Fig. 13 is a side elevation looking toward the bottom of Figs. 11 `and 12.y 1 er j n Fig. 14- is a plan `view of the ejectorplate.

Fig. 15 is an end view thereof. j

4, 1926. Serial No.146,200.

Fig. 16 is a longitudinal section through the lower die block reversed and showing the use of the ejector plate.

Fig. 17 is a top plan'view ofi the or female die block.

Fig. 18 is a front elevation of a gang plate which maybe ymolded in the die illustrated.

Fig. 19 is `a transverse section thereof Substantially on line 19-19 of Fig. 18, and

Fig. QOis a rear elevation of therportion adjacent one end of this plate. Y

flower It is common practice where a number ofv electrical devices are to be ,operated or used at. a single station, to mount' them side by `side ina single Cutletbox and, of, course, thelength ofthe box willfdepend upon the number of the devices or fixtures used, It is also usual in these installations touse a single cover or faceplate for the entiie installation orl gang in a single box, and it will, therefore, be apparentthat if a die is made for eachplate `it will require as many dies as there-are plates used, there being a die for a single plate, another die for a double plate, Vand so on up to the maximumrsize of gang installationfused. `It will beV obvious that this large number of dies would involve considerable expense and also would' require consider- Iable storage space.` I have Yovercome these objections by making a die in which anysize of gang vcover plate may be made from a plate required for afsingle fixture up to the plate required. for, the maximum number 'of lixtures. In the die illustrated in the drawings I may make a plate for a single switch or I.y

Ymay make a. plate for a twelve gang installation using twelve switches in a single outlet box, or I vcan make theplate for an installa- CONNECTICUT Y tion comprising any intermediate number of switches. Y j

This diey as illustrated comprises a lower portion including a lower or female die block 21 and a bottom plate2z2,` and an upper die block comprising a 'support 23 and one or more die sections 24,- 25, 26, 27 and 28. It will be understood that in making the plates any one of these sections .or any combination *thereofl mayA be,l used depending upon the length of the plate required. As illustrated thesection 24 alive' gang section, that is,

it is of a length to mold one side of a 'plate required for ve gangs, or, that is, five switches in the specific construction shown. Section is a three gang section, that is, it is of a length and shape to mold the section of plate for three switches. Section 26 is a two gang section. Section 27 is a one gang section used in an intermediate portion of the plate, and section 28 is a one gang section used at the outer end of the plate. These Sections are all detachably mounted on the under side of the support 28 by any suitable means, such as screws 29, and these attaching screws are so located as to be used for any section. Dowel pins 29 are also used to accurately position the sections. lt will, therefore, be apparent that if l omit, for example section 2T, which is a one gang section, and shift section 28 next to 'section 26, l can make an eleven gang plate; while if l omit section 25, which is a three gang section, and section 27, which is a one gang section, and move sections 26 -and 28 over adjacent'section 24, l can'malre an eight gang plate, and so on throughout the entire range from one to twelve, or from one to the maximum number of gangs for which the die is constructed.

In the form of cover plate for which the die illustrated is designed, the plate 230, as shown in Fig. 18, has a front surface 31 which is substantially fiat and is provided with a bevel 32 extending throughout its periphery. It alsohas rectangular openings 33 for the operating lever of the switch and which openings are surrounded by a depression having beveled side walls 34. At the opposite ends'of each opening is also a countersunlr opening 35 for the usual attaching screws, it being understood that there is ordinarily a pair of these screws for each device or fixture. On its rear surface the plate is usually provided with longitudinal and transverse strengthening ribs 36 and 87 respectively, as indicated in Fig. 20. As each fixture in the box, in the present illustration the switches, occupies the same space, it will, of course, be apparent that the openings 33, the screw openings 35 and the transverse strengthening ribs are uniformly spaced throughout the length of the plate, or, in other words, they are duplicated for each fixture. I, therefore, maire the lower die block 2l with the bottom face 38 of the recess or chamber 39 with upwardly extending 'l projections or raised portions 40 shaped and located to correspond with the openings and bevels 33 and 34 in the plate, and in the present instance there are twelve of these lugsas the maximum capacity of the die-illustrated is a twelve plate. The bottom wall of the die block 21 is also provided with openings 4l located to correspond with the location of the screw openings 35, and these openings are adapted to receive pins 42 mounted on the bottom plate 22. The upper ends of these pins are beveled or tapered at 43 and have a cylindrical projection 44 at the smaller end thereof, and the length of these pins is preferably such that the largest part of the taper is in substantial alignment withthe bottom surfacef38 of the recess corresponding to the front wall of the plate to be molded and is'of a height so that they just project through the moldedplate,l that is, the length of the taper 43 and the projection'44 may be the same as the thickness of the plate SO at the location of the screw openings. lf dill'erent shaped openings are desired the pins will be shaped accordingly.

As is ordinary in forming these kinds of plates, to give a neat and attractive appearance they are beveled at their ends and longitudinal side edges, as indicated at 32, Figs. 18 and 19, and also in Figs. 2, 3 and `16. Therefore, the section 24 of the upper die block which is used `to mold the top of the plate at one endis correspondingly shaped at vthis end whilethc section -28 which is used to mold' the other end of the plate is also correspondingly shaped at its opposite end. The intermediate sections, however, 25, 26 and 27 are used only to mold intermediate portions of the plate and they-are, therefore, shaped the same at both ends. .The lower or inner surfaces of these sections are provided with grooves to form the ribs 36 and 37 on the back side of the plate 30, or that is, the top side when it is in the die, and they also have vprojections or raised lugs 45 which will form recesses 46 in the rear Vface of the plate and adjacent the screw openings to receive thel head of the usual attaching yolres, not shown, ordinarily used in this `type of constructionto support the electrical devices in the outlet box, and which also have threaded openings to receive the 'attaching screws which pass through the openings 35. f rIhis construction is not illustrated as it is the usual construction and forms no part of my present invention.

It will also be-apparent from Figs. 2 to 5 that the opposite ends of the die block 2l ar shaped to form a bevel at the ends of the plate 30. However, as there is no surface for forming this bevel intermediate these two ends, if it is desi-red to mal-:ea plate of less length than the maximum, that is, in the present illustrations plate of less than twelve gangs, some means must be provided to form the bevel on the end of this plate opposite to the end 47 ofthe block` 21'. This is done by means of a filler block 48. This is a block which is adapted to extend into the recess or chamber 39 and has side wings 49 adapted to rest on the top surface 50 of the block 2l at the opposite sides of the recess, and it may be secured in different positions along the length of this block by means of screws 5l and dowel pins 52, there being, of course,'openings 53 and 54 suitably spaced along the sides of the die block 2l to properlyflocate this filler block `for diiferent lengthsgof platesto be gmolded.

'Ihis block when jin'position .engagesthe outer edgeabeveled rib or eX/tensionv fwhichien-` gages thesurjface 38. o .f-the recess and forms the bevelatthat-.gend ofthe molded'plate. i

vThe operation kis Aas-follow's: The die Vsections 24, 25,26, 27 and 28 or any number of them are secured to the support 23in the proper position as above described for the size of plate 30 which it is desired to mold, and the ller block 48 is properly positioned in the lower die block 21 to' coact with the section 28 to form that end ofthe plate. The bottom plate 22 is placed under the lower die block with the pins 42 in position, as shown in Fig. 2, with their upper tapered ends pro- 39. A required amount of insulating material, for example, powdered bakelite, is then placed in the recess or chamber 39 over the surface thereof and then the top die block is inserted as shown in Figs. 2 and 3. This top block is properly positioned relative to the lower die block and maintained in this posi-v tion by studs 58 carried by the block and adapted to enter the holes 59 in the lower die assembly may thenbe placed under pressure between the two heated plates of a press, or the whole die may be heated before being placed in the press in order to heat the molding material. The press will press the two sections of the die together and properly mold the plate 80. The die is then removed from the press and the top die block comprising the support 23 and the die sections 24 to 28 may be removed by lifting it ofi. from the lower section. The molded plate may have a tendency to stick in the lower die block. It may be easily removed, however, by inverting this die block 21 after the upper die block has been removed to the position shown in Fig. 16, and then the bottom plate 22 with the pins 42 may be removed. I then place on this die block the ejector plate 56, which ymay be a block of metal, and it carries a plurality of pins 57 correspondingin size and position to the pins 42, but of greater length so that as they are placed in position with the ends of the pins in the countersunk openings 35 in the molded plate the ejector plate 56 will be located somewhat above the bottom wall of the block 21. If noW a pressure is placedon thel top of this ejector plate the pins 57 will force the molded plate from the die block, or the same effect may be secured by lifting the die block 21 and'ejector plate 56 a short distance and allowing them to drop, when the mass of the plate 56 will force the molded plate 30 from the die.

It will be apparent from the foregoing dei smallest `toethedargest ,for which the die isV designed, fandI, therefore, lneed Ito construct o'nlya single ldiete moldall 'of these different fsizesiof Kplates instead 'of'.being required to makea separate die for eachsize o'fplate.v It will also, of course, be understoodftha't, al'- though I have -sh'o'wn the bottom surface B8 of the recessinjthe 'lower 'die block andthe Vlsurfaces ofthe die sections "ofthe `upper Vdie block, shaped to form ,a v{plate'for toggle switches-'having la swinging lever, I-may 'so shape `these surfaces as to `form .plates for y push switches orotherftypes 'o'fs'witches, or I may shape them to fo'rnrpla'tes.for other types `of :electrical 'devices l asI receptacles land -so forth.

'Having thus set forth the nature of my invention, what I claim` is: jecting above the bottom surface of the recess into Athe element desired, thev inner vmember including a supportanda Vplurality of die seotionsdetachably secured to the support size ofthe element molded beingdetermined by the size and number of thesectio'ns used. block and be guided thereby. The whole die f2. Ina diefoi 'mol-ding insulating material orchambe'r Ito receive'thematerial to'be molded, andthe Qot'her block'includingv a support andra. Vpllrlrality ofl die sections arranged side adapted to cooperate :tojm'oldthe material Y each conforming toy atleast as'in'glegang,`the

by sideja'nd .adapted to `enter said recess veach `conforming'to a single' gang or a multiple thereof, .and means for detachably ,securing theldie sections to the ysupport .at different ,positions to l'adjust(the .effective length .of

iifiolizleld,\` ,v y 3. In a die forr molding insulating mate*A rial into `a one4 pie'cemu-lti'fga'ng' coverplate,

f afpair ofdieblocks, one yof salidfbloks being ,p'rovidedwithla lrecess or chamberto'receive ftheV lma'terialtobe molded, 'and the other'block 'havingg'a die 'portion tol extend into the, re-

latterV block Vincludingv means' Vto adj-ust the length ofsaid dieportion, a filler block adaptl ed to cooperate with one end of .said ldieportion to formv an end of theplatemolded, and

[means for .securing `the `fillerb'loclz vin the recess adjacent lan end ofthe -d-iefpo'rtion.

4. Infa'die for molding insulating material- -plate# andthe other `blockhaving a die portion 'to extend into the recess .to cooperate Vwith the wallsthereoft shapethe other-side; of said fpl'a'tepsaidl latter block" including cesstofco'operate withthe walls thereof, said Y "blocks, 'one of 'said 'blocks lbeing provid-ed les 'ineanstoadj ust the length of said die portion to increase or decrease the number of gangs in the lfinished plate;

5'. In adie'ior inoldinginsulating material intofal single 'article,' a pair of" diebloclrs, one Vof saidblocls beingprovidedwith 'a' recess or chamber to receive thematc'rial to be' mold* ed, and the other block'cornprising a'support and a die portion comprisinga"y plurality of block inthe recess orming'an `end piece te adie yblockv anda' shiftable liller blocln' and means forfsecuringtheiillerblock'to the die block in different positions'and adjacent an end die: lSection5-the sizeof the element; being determined by themovement of the filler block and number of `'sections rused;

In testilnonyfivhereof I ailiX my'signature. "i TONJES BOTH.:

j() fsectionsfdetachably "securedv tothev support and adapted to enter the recess', 'and a'filler cooperate with said diev portion to form 'an endof they articlev molded, and meansl forse- 'curing the iller block tothe 'first block in diierent positions and adjacent an endf'oflthe i die portion. .A j l e 6. In a die for molding ,insulating niaterial, a die block having a'lrecessor'chamber having a bottomivall shaped to 'forni one face of a one piece -gang'cover platefor electrical V ixtures, a seconddie'bloclr comprising a support and a' die portion includingv avplurality of separate sections detachably secured to the support, the sections being' adapted to` f enter theY recess" and vshaped on their inner faces to form the other side of the gang plate,

and each section being Aformedfto'form the l l surface ofthe plate requiredffor atfleastone ixture.

rial,V Aa die block Llmving a 'recess 'or 'chamber having a bottom V`WallA shap'e'rdi to forni one face Vdie foi? melding insulating filate- 1 of a' one piece gang' cover plate for va pl'uy v rality'of electrical devices; fa second die'block i comprising I a: support and a plurality of die sections detachably secured to saidsupport to extend into the recess,each section -Vbeing shaped on its inner face toform thev rear surf face'of a length'of platefc'orrespon-ding to 'a multiple of the length used for each device. y Y' 8. In a die for molding insulating'material; a die block havingajrecess Aor chamber havinga bottom Wallshapeld to ormonelace f r, of a` one piece gang cover`pl'ate`or ajplurality oz electrical devices', a'second die block comprising a support' and a plurality o'fldie .l

sections detachably secured to said support to lextend into the recess,iv each section 'being 5oy shaped onitsinner face to form the rear surface' ofa vlengthfoit;plate corresponding tolfa multiple'o'f' the. lengthfusedlor Veach device,' and aller blocks'ecnredrin therecessy to cooperate `With the Lend dief `Section to :form an end of tlieplate; and meansjto secure the liller block indifferent adjusted positions and adjacent onei'isideof the end 'die 'seCtioir' to the support.` the 'outer' member including 9. kIn a dieiorinolding aone piece yeleian 

